Methods for making soft or firm/semi-hard ripened and unripened cheese and cheeses prepared by such methods

ABSTRACT

Methods and systems for preparing soft or firm/semi-hard cheese are provided, as well as soft or firm/semi-hard cheese prepared by the methods. The methods typically involve the formation of a slurry that contains blended or molten cheese curd. A variety of ingredients can be introduced into the curd used to prepare the slurry, the slurry that is formed, or at other stages along the manufacturing process to tailor the performance and nutritional characteristics of the final cheese product. The slurry in some methods is directly processed to form a final cheese product. In other methods, the slurry undergoes various types of processing to achieve certain desired composition or performance requirements.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.11/121,398, filed May 3, 2005, now U.S. Pat. No. 7,579,033, and whichclaims priority to U.S. Provisional App. No. 60/568,017, filed May 3,2004, and titled “Methods for Making Soft or Firm/Semi-Hard Ripened andUnripened Cheese”, the entire contents of which are herein incorporatedby reference for all purposes.

This application is also related to the following U.S. patentapplications, all of which are incorporated herein by reference in theirentirety for all purposes:

1. U.S. Provisional App. No. 60/568,029, filed May 3, 2004, entitled“Soft or Firm/Semi-Hard Ripened or Unripended Cheese and Methods ofMaking Such Cheeses,”

2. U.S. Provisional App. No. 60/568,022, filed May 3, 2004, entitled“Soft or Firm/Semi-Hard Ripened or Unripened Blended Cheeses and Methodsof Making Such Cheeses”;

3. U.S. patent application Ser. No. 11/121,537 filed on the same day asthe present application, and entitled “Cheese and Methods of Making SuchCheese,”; and

4. U.S. patent application Ser. No. 11/122,283 filed on the same day asthe present application, and entitled “Blended Cheeses and Method forMaking Such Cheeses,”.

BACKGROUND

Recently there has been an increase in the demand for cheeses that havewidely differing performance characteristics. This particular demand isdriven in part by the increasing variety of prepared foods in which suchcheeses are included. In fact, there often is a need for differentperformance qualities even for foods of the same general type because ofthe different ways cheese is utilized or because the cheese is exposedto differing cooking environments or conditions. Pizzas illustrate thispoint well because there are so many different types of pizzas. Pizzas,for example, have widely differing crusts, including thick, thin, orsomewhere in between. The cheese can also be exposed or wrapped in theedge of the crust. Furthermore, the crust may be completely uncooked orit may be parbaked before being put in the oven with the cheese. Each ofthese variables potentially impacts the composition of the cheeserequired to provide satisfactory performance.

Demand for cheese with varying performance characteristics is alsodriven in part by the significant increase in the different types ofbaking equipment and conditions that are being used to prepare foodproducts containing soft or firm/semi-hard cheese. Some bakingoperations, for instance, require relatively high oven temperatures(e.g., in the range of about 350 to 950° F. (177-510° C.)) with shortbaking times (e.g., in the range of about 30 seconds to 15 minutes).Such conditions may be used, for instance, in an impingement oven whenbaking a pizza having a thin crust. Other ovens, such as deck ovens, incontrast, sometimes use a relatively long bake time (e.g., about 6 to 60minutes) and a correspondingly lower oven temperature (e.g., about 300to 750° F. (149 to 399° C.)). Instead of baking, some foods topped withor including soft or firm/semi-hard cheese are prepared by microwaving(e.g., about 1-6 minutes).

Consumer demand for cheeses with improved nutritional content (e.g.,nutritionally balanced, lower fat) has also increased the demand for newvarieties of soft or firm/semi-hard cheese.

There are a variety of challenges to providing cheeses that have acomposition which satisfies the desired performance characteristics andnutritional qualities. For instance, it can be difficult to obtain thedesired concentration level of some ingredients in a cheese. Anotherproblem is developing a process that activates the latent functionalproperties of certain ingredients. Another problem is that many methodsfor preparing soft or firm/semi-hard cheese involve the loss ofsignificant quantities of some cheese components during processing. Thiscan occur, for instance, when such cheeses undergo the heating andstretching process of the pasta filata process. Often the heating isconducted in heated water, which can remove significant amounts ofcheese ingredients.

In view of the demand for cheese and the foregoing shortcomingsassociated with some existing methods for preparing cheeses with thedesired performance characteristics, there thus remains a need foradditional methods for preparing cheeses of various types.

SUMMARY

A variety of methods for preparing soft or firm/semi-hard ripened orunripened cheese are provided. Cheese produced by the methods andsystems for conducting the methods are also provided.

Some cheese manufacturing methods involve blending a cheese curd and oneor more ingredients together to form a slurry. The slurry is processedby performing one or more processes selected from the group consistingof cooking the slurry, subjecting the slurry to high shear conditions,homogenizing the slurry, and adjusting the moisture content of theslurry. Once the slurry has been processed, one or more additionalingredients can be mixed into the slurry to form an admixture. Theresulting admixture is formed into a cheese. In some methods, the slurryis cooked in the absence of exogenous water.

The ingredients blended into the slurry can be selected from a widevariety of ingredients including, but not limited to, nonfat dry milk, amilk protein, an acidity regulator, an acid, an anticaking agent, anantifoaming agent, a coloring agent, an emulsifier, an enzymepreparation, a flavoring agent, a firming agent, a food protein, agelling agent, a preservative, sequestrants, a stabilizer, a starch, athickener, an oil, a fat, a cheese powder, a salt, a nutritionalsupplement, an acid, an enzyme, a neutraceutical, a carbohydrate, avitamin, and a mineral. Examples may further include procream, wheycream, a dairy solid, and foodstuffs of vegetable, fruit and/or animalsource. The foodstuffs may include fruit, vegetables, nuts, meat, andspices, among other foodstuffs.

Other methods for preparing cheese involve blending a cheese curd, andoptionally water and/or one or more ingredients, to form a slurry. Theslurry is processed by cooking the slurry and performing one or moreprocesses selected from the group consisting of subjecting the slurry tohigh shear conditions, homogenizing the slurry and adjusting themoisture content of the slurry. The processed slurry is then shaped andcooled to form the soft or firm/semi-hard cheese.

Still other cheese preparation methods involve providing an admixturethat comprises a cheese curd and one or more ingredients selected fromthe group consisting of a starch, a dairy solid, a gum and a celluloseagent. The admixture is then shaped and cooled to form the soft orfirm/semi-soft cheese. In some methods, the concentration of the starch,the dairy solid, the gum or the cellulose agent in the admixture issufficient such that the soft or firm/semi-hard cheese that is producedhas one or more of the following characteristics (i) a starchconcentration of at least 0.1 wt %, (ii) a dairy solid concentration ofat least 0.1 wt %, or (iii) a gum or cellulose agent concentration of atleast 0.1 wt %.

Methods for preparing a slurry that can be used in the preparation of asoft or firm/semi-hard ripened or unripened cheese are also disclosed.Some of these methods involve blending a cheese curd and one or moreingredients together to form a slurry. The slurry is then processed byheating the slurry to a temperature of about 90° F. to about 293° F. andperforming one or more of the processes selected from the groupconsisting of subjecting the slurry to high shear conditions,homogenizing the slurry, and adjusting the moisture content of theslurry to about 36 to 65 wt. %, thereby forming the heated slurry.

Also included are slurries that can be used in the preparation of a softor firm/semi-hard ripened or unripened cheese. Some slurries include acheese curd and one or more ingredients, wherein the one or moreingredients are selected from the group consisting of a starch, a dairysolid, a gum and a cellulose agent, and wherein the slurry may have oneor more of the following characteristics (i) a starch concentration ofat least 12 wt % or (ii) a dairy solid concentration of at least 12 wt%, or (iii) a gum or cellulose concentration of at least 12 wt %.

Cheese manufacturing systems are also provided. Certain of these systemscomprise a slurry preparation system, which itself includes a blenderadapted to blend a cheese curd and one or more ingredients together toform a slurry and a first dispenser operatively disposed to introducethe one or more ingredients into the slurry. The slurry preparationsystem also includes a subsystem comprising at least one of thefollowing units (i) a cooker adapted to heat the slurry to a temperatureof about 90° F. to about 293° F.; (ii) a shear pump adapted to subjectthe slurry to high shear conditions; and (iii) a homogenizer adapted tohomogenize the one or more ingredients in the slurry; and (iv) anevaporator adapted to adjust the water content of the slurry to about35-65% by weight, wherein at least one unit is in communication with theblender and the units within the subsystem are in fluid communication.

The manufacturing system also includes a second dispenser and a mixeroperatively disposed to receive the slurry from the slurry preparationsystem and to receive one or more ingredients from the second dispenser,and adapted to mix the slurry with the one or more ingredients to forman admixture. Finally, the manufacturing system includes a finalprocessing system operatively disposed to receive the admixture andadapted to form a final cheese product.

Soft and firm/semi-hard cheeses produced by the methods disclosed hereinare also provided.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A depicts one example of a method for preparing a soft orfirm/semi-hard cheese that involves a cooking step that is conducted inthe absence of exogenous water.

FIG. 1B provides another exemplary method for preparing a soft orfirm/semi-hard cheese in which ingredients can optionally beincorporated into a curd and then again later in the process after thecurd has been processed.

FIG. 2 shows an exemplary method for preparing a soft or firm/semi-hardcheese that involves cooking a blended cheese curd and an additionalprocessing step.

FIG. 3 illustrates another exemplary method for preparing a soft orfirm/semi-hard cheese that involves addition of ingredients at twostages along the preparation process, specifically to the initial cheesecurd and to a slurry containing blended curd formed after processing ofthe cheese curd.

FIG. 4 depicts another example of a method for preparing a soft orfirm/semi-hard cheese that illustrates exemplary slurry processingsteps.

FIG. 5 depicts an exemplary cheese preparation system that utilizes acooker that heats curd in the absence of exogenous water.

FIG. 6 shows an example of systems that can be utilized to prepare thesoft or firm/semi-hard cheeses that are provided herein.

FIG. 7 shows another example of a cheese preparation system that can beused to prepare the soft or firm/semi-hard cheeses that are provided anddepicts certain units in the slurry preparation system.

FIGS. 8A-B show cross sectional samples of finished cheeses.

DETAILED DESCRIPTION

I. Definitions

A “soft or firm/semi-hard cheese” as used herein generally includescheeses that have a percentage moisture on a fat free basis (MFFB) ofabout 54% or more, by weight. The term includes firm/semi-hard cheesesthat have a MFFB, for example, of about 54% to about 80%, by wt., andchesses with a MFFB, for example, of about 58% to about 75%, by wt. Theterm encompasses a variety of well known cheeses including, but notlimited to Colby, Havarti, Monterey Jack, Gorgonzola, Gouda, Cheshireand Muenster, which are examples of “firm/semi-hard cheeses.” Alsoincluded in the term are “soft” cheeses, which may have a MFFB ofgreater than about 60%, by wt. A variety of mozzarella cheeses areincluded by the term; these can be in the soft or firm/semi-hardcategory, or in between the two, depending upon their moisture content.Standard mozzarella, for example, is a soft cheese, part-skim mozzarellais between soft and firm/semi-hard, and low-moisture mozzarella andlow-moisture part-skim mozzarella are both designated as firm/semi-hardcheeses. The term soft or firm/semi-hard as used herein includes cheesesmeeting the CODEX definition of a soft or firm/semi-hard cheese. Theterm also includes soft or firm/semi-hard cheeses as defined by otherlocal, regional, national or international agencies or organizations.

Cheeses within the “soft or firm/semi-hard” category as defined hereincan be prepared using a variety of methods, including conventionalmethods, as well as by “alternative make” provisions. The term includes,for instance, cheeses made by a process in which a cheese curd is heatedand kneaded to improve the stretchability or stringiness of the finalcheese, provided the cheese falls within the MFFB parameters set above.This process and related processes are sometimes referred to as a pastafilata process of manufacturing. Cheeses made by this process are knownunder a variety of names, including mozzarella, pasta filata, provolone,Mexican style, scamorze, and pizza cheese. Cheeses made by alternativemake procedures are prepared by alternative methods of making cheeses,so long as the procedure produces a cheese having the same physical andchemical properties of the type of cheese made by a specified process(e.g., a process specified by a regulatory agency) and falls within theMFFB parameters as set forth above.

The “soft” and “firm/semi-hard” cheeses that are provided includestandard and non-standard cheeses having the foregoing moisturecharacteristics. Standard cheeses are those that satisfy the standardsas set forth by a regulatory body with respect to a particular type ofcheese. A non-standard cheese is one whose composition does not meet thestandard. A soft or firm/semi-hard cheese can also be a processedcheese. A soft or firm/semi-hard cheese can also be ripened orunripened.

“Mozzarella” cheese has a minimum milkfat content of 45% by weight ofthe solids and a moisture content of more than 52% but not more than 60%by weight. “Low-moisture mozzarella” cheeses have a minimum milkfatcontent of 45% be weight of the solids and the moisture content is morethan 45% but not more than 52% by weight. “Part-skim mozzarella” has amoisture content of more than 52% but not more than 60% by weight, and amilk fat content that is less than 45% but not less than 30% calculatedon the solids basis. “Low-moisture part-skim” mozzarella has a moisturecontent of more than 45% but not more than 52% by weight and a milkfatcontent, calculated on the solids basis, of less than 45% but not lessthan 30%. Further details regarding these various mozzarella cheeses isprovided by 21 C.F.R. §1.33.155-133.158.

II. Overview

Methods and systems for preparing a variety of cheese products such assoft or firm/semi-hard cheese are provided. The methods typicallyinvolve the formation of a slurry that contains blended or molten cheesecurd. A variety of ingredients can be introduced into the curd used toprepare the slurry, the slurry that is formed, or at other stages alongthe manufacturing process to tailor the performance and nutritionalcharacteristics of the final cheese product. The slurry in some methodsis directly processed to form a final cheese product. In other methods,the slurry undergoes various types of processing to achieve certaindesired composition or performance requirements.

The methods, for instance, can be used to introduce various ingredients,either in the slurry and/or with another component of the cheese, tocontrol: 1) melt and flowability of the final cheese product, which is ameasure of how well the cheese melts and flows into a homogenous mass,preferably with little or no individual shreds of cheese stilldetectable; 2) stretch, which is a measure of the ability of the cheeseto form interconnected strings when the heated cheese is pulled; 3)texture, which is a measure of chewiness and smoothness; 4) coloring,which is a measure of the actual color of the melted cheese; 5) blistercharacteristics, which may include size, color and extent of coverage;and/or 6) nutritional composition.

In some methods, the slurry is processed so it is in a form that confersuseful properties on the final cheese product and/or facilitatespreparation of the cheese. Some methods, for instance, utilize a heatedslurry that may also have been sheared and/or homogenized. Suchprocessing can influence the performance of the final cheese product invarious ways. For example, this processing can be used to achieve higherconcentrations of certain ingredients in the final cheese product ascompared to traditional approaches. Without intending to be bound bytheory, it is believed that the shearing and homogenization process canreduce particle size of the components of some cheese ingredients. Theseresulting particles because of their reduced size are thus better ableto become incorporated into the overall cheese matrix, thereby allowingmore ingredients to be introduced into the final cheese product.

The reduced particle size also makes it easier to remove excess waterduring the manufacturing process to the level desired in latermanufacturing stages. The ability to control water content is animportant factor in being able to regulate the stability of cheese andthus its shelf life. Reduced particle size also facilitates forming acompact cheese that can be easily processed (e.g., shredded, sliced, ordiced). Shearing and homogenization can also be important in reducingthe viscosity of the slurry, which aids in various processing steps(e.g., transport of the slurry).

Use of a slurry that has been heated, sheared and/or homogenized duringthe manufacturing process also is useful in activating, exposing thefunctionality and/or in hydrating the ingredients, such that theingredient has different properties than the corresponding unheatedingredients. As a specific example, it can be difficult to incorporatenon-fat dry milk into a cheese as a dry powder in certain cheesemanufacturing methods because the non-fat dry milk never becomes fullyhydrated. This makes the non-fat dry milk susceptible to burning whencooked, for example. By using certain of the slurry-based methodsdisclosed herein, ingredients such as non-fat dry milk can be betterhydrated, thus mitigating against the burning problem. The hydration ofother ingredients can have other beneficial results.

Some methods also involve a process in which the water content of theslurry is adjusted. This is useful because the water content in a cheeseis an important factor in stability, shelf life and the ability toslice, shred and dice the final cheese product.

In sum, the use of slurries to introduce ingredients into cheeses atcertain stages of the manufacturing process can be used to help tailorthe performance and nutritional characteristics of the final cheeseproduct.

II. Methods for Preparing Soft or Finn/Semi-Hard Cheeses

A. General

Some of the methods for preparing a soft or firm/semi-hard cheese thatare provided herein involve the general approach shown in FIG. 1A.Method 20 which is shown in this figure involves providing a cheese curd22 and then cooking 24 the cheese curd in the absence of exogenous waterto form a slurry containing molten cheese (mass of molten cheese). Thisslurry is subsequently formed 26 into the final soft or firm/semi-hardcheese product. In some variations on this general approach, variousingredients such as described herein can be incorporated into the cheesecurd before cooking and/or into the slurry after cooking. Methods ofincorporating ingredients into a cheese curd and then processing it thatcan be utilized in some methods disclosed herein are described incopending U.S. application Ser. No. 10/300,019, now U.S. Pat No.7,169,429 which is incorporated herein by reference in its entirety forall purposes.

The term “exogenous water” as used herein refers to water that is usedto bathe the curd and which is subsequently separated from the moltencheese mass that is formed. A problem that can be associated withcertain methods that utilize exogenous water to heat the curd is that,when the water is separated, valuable protein, fat, and other solidsthat otherwise would be bound up in the finished cheese are removed.Various cookers can be used to heat the cheese curd in the absence ofexogenous water. One option is the RotaTherm™ cooker available from GoldPeg International Pty. Ltd. (Moorabbin, Vic, Australia).

Another general method is illustrated in FIG. 1B. Method 40 includes aslurry preparation process 102, which includes providing 42 a curd,blending 105 the curd, optionally with one or more ingredients, to forma slurry, and processing 110 (e.g., cooking, shearing, homogenizing,adjusting moisture content) the slurry. One or more additionalingredients are then mixed 172 into the processed slurry. The slurry isthen finally formed 180 into the final soft or firm/semi-hard cheeseproduct. Although method 40 includes the incorporation of ingredientsinto the cheese curd and the processed slurry (see processes 105 and172), other methods may not include one or both of these steps.Furthermore, although this particular method shows the addition ofingredients during the blending 105 process, ingredients can in othermethods be added at any stage during the slurry preparation process 102(e.g., during processing of the slurry).

Additional detail regarding these general steps and further examples ofspecific methods are provided in the following sections. Then examplesof specific methods are provided.

1. Slurry Preparation and Processing

The process of preparing the slurry generally involves: 1) blendingcheese curd, and optionally a liquid (e.g., water, milk, cream or oil)and/or one or more ingredients, to form the slurry, and 2) optionallyprocessing the slurry. So, in some methods, the slurry that is producedis directly processed into a final cheese product. In other methods, theslurry is processed to adjust the slurry to a form that mixes well withthe ingredients that are added and/or to create a composition that issuitable for later processing.

The cheese curd utilized in the blending process can be prepared, forexample, from pasteurized cow's milk, buffalo milk, goat's milk, orother milk source (e.g. concentrated milk, reconstituted milk or milkprotein powders). The milk is acidified to form cheese milk. Theacidification step can be performed either microbially, directly, or acombination of microbial and direct acidification. Microbialacidification is accomplished by the addition of a starter culture ofone or more lactic acid-producing bacteria to the milk, and thenallowing the bacteria to grow and multiply. When making a mozzarellavariety cheese, a bacterial starter culture composed of coccus, rods, ora combination of both is preferably used. In some methods ofacidification, an acid added as a processing aid, such as acetic acid(e.g., vinegar), phosphoric acid, citric acid, lactic acid, hydrochloricacid, sulfuric acid, or glucono-delta lactone (GdL), lactobionic acid,etc., is added to standardize pH and is followed by addition ofmicrobial starter to complete the acidification process. Followingaddition of the microbial and/or GRAS acids, the cheese milk iscoagulated to form a coagulum that consists of cheese curd and whey.Rennet or other suitable enzyme(s) is typically added to the milk toenhance the coagulation activity. The resulting coagulum is cut and thewhey drained off to obtain the cheese curd. The curd can optionally bescalded (cooked) for about 0.08 to 1.0 hours at about 86-120° F. (30-49°C.), at which point the curd is ready to undergo the heating andkneading operation.

When dairy milk is used as a precursor, the sweet cream fraction of themilk, or a portion thereof, may be separated and replaced by other typesof creams and/or fats prior to acidification. For example, the sweetcream may be replaced by whey cream and/or pro-cream (i.e., a mixture ofprotein and cream) that is included with the whey fraction that isseparated from the cheese curd. The replacement of the dairy sweetcream, or a portion thereof, with the whey cream and pro-cream reduceswaste by making use of the whey cream and pro-cream, as well as makingthe higher value sweet cream available for sale in the marketplace.

The term “cream” means the liquid milk product high in fat separatedfrom milk which may have been adjusted by adding thereto: milk,concentrated milk, dry whole milk, skim milk, concentrated skim milk,nonfat dry milk or other GRAS ingredients. “Whey cream” is the liquidmilk product high in fat separated from whey (cheese, casein, or other),which may have been adjusted by adding thereto: whey, concentrated whey,dry whey, or other GRAS ingredients. “Procream” is the liquid milkproduct high in fat collected as retentate from a whey filtrationprocess such as microfiltration which may have been adjusted by addingthereto: whey, concentrated whey, dry whey, or other GRAS ingredients.

The process of blending the curd, and optional liquid (e.g., water)and/or ingredient(s) together can be accomplished by a variety oftechniques. One approach is to use a horizontal twin screw (auger)blender. Other options include the use of a ribbon blender or forcingthe slurry through a pipeline that includes a series of pumps and staticmixers. The curd, optional water and/or ingredient(s) can be blendedtogether as part of a single step. Typically low shear treatment is usedin this mixing step, but higher shear may be used if curd particle sizereduction is desired. The blending operation occurs at between 60-130°F., and continues until a homogeneous mixture is obtained.

Slurry processing typically includes cooking the slurry, typically toabout 90-293° F. or 100-250° F., but this is not required in somemethods. It can also optionally include one, two or all of the followingprocesses: (1) subjecting the slurry to high shear conditions, (2)homogenizing the slurry, and/or (3) adjusting the water content of theslurry, usually to about 35-65, or 45-60 wt. %.

Different methods can incorporate different combinations of two or allthree of the foregoing optional processes. So, for example, in somemethods, the pre-mixing processing involves (1) and (2) but not (3).Other processes include (1) and (3) but not (2). Still other pre-mixingprocesses include (2) and (3) but not (1). And still other processesinclude (1), (2) and (3). The other remaining combinations can also beutilized depending upon the particular requirements of an application.The other remaining combinations can also be utilized depending upon theparticular requirements of an application. In some instances, it issufficient to simply shear the slurry without homogenizing it. But thepre-mixing process may involve both, in which case the slurry is firsttypically sheared and then homogenized, although the order can bereversed.

In some methods, some slurry processing steps are optionally carried outat the same time (e.g., subjecting the slurry to high shear conditionswhile homogenizing the slurry; or heating the slurry while subjecting itto high shear conditions and/or homogenizing the slurry). Cooking canoptionally be performed during shearing and/or homogenizing. Cooking canalso be done before or after the shearing and homogenizing processes, ifthey are included in the overall method. In general, however, the slurryprocessing steps conclude by adjusting the water content of the slurry.

Heating of the slurry can be accomplished in a variety of ways,including 1) direct steam injection, 2) indirect heating via an indirectheat exchanger, mechanical energy, or radiation (e.g., microwave). Thesteam injection option generally involves releasing live steam into thecooking chamber. When live steam is used, the steam condensate isabsorbed by the curd and forms part of the final mass of cheese.Indirect heating can be accomplished, for example, by conduction,through the wall of the cooker, e.g., by use of a hot water jacket. Asnoted above, some slurries are heated using a cooker in which heatingoccurs without exogenous water.

Some ingredients need to be subjected to high shear conditions to becomefunctional (e.g., hydrated or converted to a form that displaysfunctional binding groups). High shear conditions as used hereingenerally refer to conditions in which the slurry is subjected to ashear rate of 10,000-500,000 s⁻¹. In some methods, the slurry istypically sheared by passing the slurry through a shear pump, at atemperature of about 90-293° F. (32-145° C.) for about 0.01-0.5 seconds.In some methods, the slurry is typically sheared by a high-shear mixeror colloid mill.

Homogenization of the slurry, if performed, generally involves a processof reducing the particle size of fluid products under conditions ofextreme pressure, shear, turbulence, acceleration and impact, to makethem more stable and have a better texture. The effect is achieved byforcing the product through a homogenizing valve at high pressure.Homogenization is accomplished in one or multiple steps. For mostslurries, two steps are sufficient. It is common that the mainhomogenization takes place in the first homogenization valve and a mildhomogenization in the second valve. The second homogenization valve willenhance the product quality. It will break down the newly formed fatglobule clusters formed directly after the first valve. Homogenizationis usually conducted at a temperature of about 90-293° F. (32-145° C.)for about 0.01-0.5 seconds.

As indicated above, if the water content of the slurry is adjusted, themoisture content is generally adjusted to about 35-65%, and in someinstances from about 45-60%. The temperature during this process istypically about 110-150° F. (e.g., 140° F.).

2. Addition of Ingredients

Ingredients of a variety of types (see below) can optionally be added tothe cheese curd that goes into making the slurry and/or at later stages(e.g., once the slurry has been processed). These ingredients aresometimes added in a dry form (e.g., as a powder), but in some instancescan be added in liquid form. Powdered solids can be added using any of anumber of conventional approaches, including sprinkling the solids intothe slurry, usually after application of ingredients in liquid form, ifany. Liquid agents or ingredients can be sprayed down onto the surfaceof the slurry.

3. Mixing of Ingredients into Slurry or Curd

Ingredients can be mixed into the curd or slurry using various mixingtechniques that are conventional in the industry. In certain methods,for example when ingredients are added to the slurry, the mixing isperformed at a temperature of about 100 to about 150° F. The temperaturein some applications is relatively high, such as between 160-180° F.(71-82° C.). In other methods, the temperature is at or slightly belowthat of pasteurization (65° C., 150° F.), for example in the range ofabout 145-150° F. (63-65° C.). Mixing is usually conducted for about2-15 or 5-10 minutes. Mixing is generally performed under low shearconditions.

4. Final Processing/Forming Slurry into Final Cheese Product

Final processing of the slurry generally involves shaping and coolingthe slurry to form a desired final product. In general, the slurrycontaining the heated and/or blended cheese curd can be formed into anydesired shape depending upon the ultimate intended use. General optionsinclude, but are not limited to, 1) forming relatively large pieces ofcheese which are packaged; 2) comminuting the cheese into smaller piecesthat are packaged without freezing but instead refrigerated; 3)comminuting, packaging and freezing the cheese, and 4) comminuting,freezing, then packaging the cheese.

In some methods, for instance, the slurry is extruded as a continuousRibbon™, which is discharged into a cold sodium chloride brine channelor tank, for example as described in U.S. Pat. No. 4,339,468 toKielsmeier or U.S. Pat. No. 5,200,216 to Barz et al. (both of which areincorporated herein in their entirety). The cheese Ribbon™ is sometimescontacted with cold sodium chloride brine (in one or more tanks orvessels) until its core temperature drops to about 75° F. (24° C.) orbelow. Then the cooled Ribbon™ can be cut into segments havingdimensions suitable for the intended use of the cheese.

Other options include: 1) floating the cheese in a coolant; 2) placingthe cheese on a perforated belt and spraying coolant on the cheesesurface; 3) placing the cheese on a solid belt and spraying coolant onthe underside of the belt; 4) transfer through a cooling chamber; and 5)refrigeration of the heated cheese.

If a string cheese is the desired product [e.g., a cheese having adiameter of about ⅛ to 1.0 inch (0.32 to 2.54 cm.)], the segments of thestring are generally about 1½ to 12 inches (4 to 30.5 cm) long. If thestring cheese is to be baked only while enclosed in pizza crust (e.g.,in a stuffed crust pizza), it typically is unnecessary to age the cheesebefore using it. If desired, the string cheese can be frozen and stored.

The warm cheese can also be molded/extruded into blocks of any of avariety of sizes that are convenient. Some blocks, for example, areabout 4 inches high, 4-8 inches wide, and 4-24 inches long.

If the finished cheese is to be used as an exposed topping for a pizza,then the continuous Ribbon™, typically is rectangular in cross section,and can be cut into loaves, for example having a width of about 4 to 36inches (10 to 92 cm.), a height of about 1/16 to 4 inches (0.15 to 10cm.), and a length of about 4 to 36 inches (10 to 92 cm.). The loavescan then be further cooled in sodium chloride brine, for example to acore temperature in the range of about 26 to 75° F., and then removedfrom the brine and comminuted, and the pieces individually quick frozen,for example by the process described in U.S. Pat. No. 5,030,470 toKielsmeier, et al., which is hereby incorporated herein by reference.

Depending on the composition of the cheese, it may be preferable tostore it for a time [e.g., about 7 to 21 days, at about 35 to 45° F. (2to 7° C.)] after it is removed from the last brine tank and before it iscomminuted and frozen. However, as described in U.S. Pat. No. 5,200,216(Barz et al.), if the process is controlled such that the cooled cheeseremoved from the brine has a moisture content of about 45 to 60 wt. %, amilk fat content of at least about 30 wt. % (dried solids basis), and acombined moisture and wet milk fat content of at least about 70 wt. %,the cheese can be frozen immediately and will still performsatisfactorily when baked on a pizza, under a variety of conditions.

The final processing procedure can also be as described in U.S. Pat. No.5,902,625, which is incorporated herein by reference in its entirety forall purposes.

B. Exemplary Methods

Utilizing the foregoing processes, a variety of different methods can bedesigned that are appropriate to a particular application. Examples ofsuch methods follow. It should be understood, however, that thesemethods are simply illustrative of other arrangements that could beutilized.

FIG. 2 illustrates one specific example of a method for preparing a softor firm/semi-hard cheese. In this particular method, ingredients areoptionally introduced during curd blending. Ingredients can also beintroduced after slurry processing (not shown). As shown in FIG. 2, inmethod 60 a cheese curd and one or more optional ingredients are blended105 to form a slurry. The slurry is then processed 110. Processing 110in this particular method involves cooking the slurry 115 and performing117 one or more additional processes. These additional processes includesubjecting the slurry to high shear conditions, homogenizing the slurryand/or adjusting the water content of the slurry. The resulting slurryis then formed 180 into a final soft or firm/semi-hard cheese product.

FIG. 3 depicts another exemplary method. This particular methodillustrates an approach in which one or more ingredients are introducedduring the curd blending process to form a slurry and after processingof the slurry. Process 80 initially involves blending 103 a cheese curdand one or more ingredients to form a slurry. Slurry processing 110 inthis instance involves performing 119 one or more of the followingprocesses: cooking the slurry, subjecting the slurry to high shearconditions, homogenizing the slurry, and/or adjusting the water contentof the slurry. The processed slurry is then mixed 172 with one or moreingredients. The slurry is then formed 180 into the desired final cheeseproduct.

Another exemplary method is shown in FIG. 4. Method 100 illustrates anumber of the various slurry processing options that can be incorporatedinto the methods that are provided. As can be seen, in method 100, theslurry preparation process 102 initially involves blending 105 cheesecurd (optionally a liquid (e.g., water) and/or one or more ingredients)to form the initial slurry. Slurry processing 110 in this instanceinvolves cooking/heating 115 the resulting slurry to about 90-300° F.This heated slurry is then subjected 120 to high shear conditions andthen homogenized 125. Thereafter the water content of the heated slurryis adjusted 130 to about 45-60 wt. %. The slurry is transferred to thecombining and mixing state 170 through the use of a pump at thedischarge of a surge hopper, which maintains the slurry at a constantvolume 131. As the slurry is transferred, it may be filtered 132 toremove any large particles formed in the slurry during thecooking/heating step 115 (or other extraneous materials), and alsoexposed to a magnetic field 133 to remove any metal fragments in theslurry generated by metal to metal contact of the moving parts of theprocess equipment.

Once the heated slurry has been heated, sheared, homogenized and/or thewater content adjusted to the desired range, one or more ingredients areadded 170 to the slurry and then mixed 175 together to form anadmixture. The resulting admixture is subsequently processed 180 to formthe final soft or firm/semi-hard cheese product. In the particularmethod depicted in FIG. 4, final processing 180 involves shaping 185 theadmixture into a desired form and cooling 190 the shaped cheese to formthe final cheese product. Although FIG. 4 shows the final processingstep to first involve the shaping process followed by the coolingprocess, this order can be reversed or performed simultaneously.

The final processing 180 of each of the exemplary methods shown in FIGS.2-4 can involve any of the processing options described above orgenerally known in the art. So, for example, in some methods finalprocessing involves individually quick-freezing pieces of the cheese asdescribed in U.S. Pat. No. 5,030,410. Other methods involve a same daydice procedure such as described, for example, in U.S. Pat. No.5,200,216. In still other methods, the cheese is not comminuted butformed into blocks that is directly packaged and refrigerated. Those ofskill will recognize that a variety of other processing options areavailable.

III. Slurry Ingredients and Non-Slurry Ingredients

A. General

A number of different types of generally recognized as safe (GRAS)ingredients can be incorporated into the slurry and optionally added atother stages of the overall manufacturing process as described herein.If added at a stage other than the slurry, most ingredients cangenerally be added as a powder or as part of a solution. The ingredientsthat are incorporated are selected, for example, to tailor theperformance, nutritional, and taste characteristics of the final soft orfirm/semi-hard cheese product. Some of the methods that are providedinvolve the addition of ingredients other than those commonly used inthe production of an analog cheese. Such methods thus omit one, some orall of the following: an oil, a fat, a protein, a starch, a sequestrantand a salt. Other methods, however, incorporate one, some or all ofthese ingredients.

As noted above, some of the ingredients included in the slurry generallyfall into two general categories: 1) ingredients that one seeks toincorporate at relatively high concentration levels; and 2) ingredientsthat need to be heated and/or hydrated to become functionalized, i.e.,to be converted into a form that has the chemical and/or physicalproperties that are important for obtaining a final cheese product withthe desired characteristics or composition. But a variety of otheringredients can also be included in the slurry.

Examples of such ingredients include, but are not limited to, nonfat drymilk, a milk protein, an acidity regulator, an acid, an anticakingagent, an antifoaming agent, a coloring agent, an emulsifier, an enzymepreparation, a flavoring agent, a firming agent, a food protein, agelling agent, a preservative, sequestrants, a stabilizer, a starch, athickener, an oil, a fat, a cheese powder, a salt, a nutritionalsupplement, an acid, an enzyme, a neutraceutical, a carbohydrate, avitamin, and a mineral. Examples may further include procream, wheycream, a dairy solid, and foodstuffs of vegetable, fruit and/or animalsource. The foodstuffs may include fruit, vegetables, nuts, meat, andspices, among other foodstuffs.

Examples and additional specific information regarding the types ofingredients that can be incorporated to tailor the performance,nutritional and taste characteristics of the final soft orfirm/semi-hard cheese product follow.

Dairy Solids. A dairy solid can be added to improve variouscharacteristics of the final cheese products such as: firming thecheese, improving water binding capacity, improving the melt appearanceof the cooked cheese, and/or increasing the blistering of the cookedcheese. Dairy solids that can be utilized include, but are not limitedto, whey protein concentrate, casein hydrolyzate, milk fat, lactalbumin,cream, milk protein concentrate, milk protein isolate, lactose, casein,whey protein isolate, hydrolyzed whey protein, denatured whey protein,skim cheese powder, natural casein isolate and nonfat dry milk. Ingeneral, dairy solids can be incorporated into the final product fromabout 0.5-25 wt. %.

Incorporation of a dairy solid such as non-fat dry milk into a heatedslurry is one approach for obtaining relatively high concentrationlevels in the final product. For example, the dairy solid concentrationin some soft or firm/semi-hard cheeses that are prepared according tothe methods disclosed herein can be at least 0.1 wt. % and in otherinstances considerably higher such as at least 10, 11, 12 or 13 wt. %,and can include, for example, up to about 16, 17, 18, 19, 20 or 25 wt. %of the final product. Thus, the concentration of the dairy solids isgenerally adjusted such that the level of dairy solid in the finalcheese product is about 0.5-25, about 3-18, about 4-16, or about 11-25wt. %.

Starches. Incorporating starches into the heated slurry is alsobeneficial in some instances because the functionality of some starchesis increased when heated, hydrated and/or subjected to high shearconditions. Once functionalized in this manner, the starch can thickenor gel to bind to proteins in the cheese (e.g., casein). In general,starch can be incorporated into the final product in the range of about0.5-20 wt. %.

Some methods add starch such that the starch concentration in the finalcheese product is at least 0.1, 1, 4, 10, 11, 12, 13 or 20 wt. %. Thus,in some instances, the starch concentration can range from about 4-20wt.% or from about 5-16 wt. % in the final cheese product.

A number of different types of starches can be incorporated into thefinal cheese product. Suitable starches include vegetable starches(e.g., potato starch, pea starch, and tapioca) and grain starches (e.g.,corn starch, wheat starch, and rice starch). Specific examples ofsuitable corn starches include dent corn starch, waxy corn starch, andhigh amylose corn starch. The starches can be used individually or incombination.

The starch can be modified or native. Modified food starches differ intheir degree of cross-linking, type of chemical substitution, oxidationlevel, degree of molecular scission, and ratio of amylose toamylopectin. Examples of some commercially-available modified foodstarches that are suitable include Mira-Cleer 516, Pencling 200, Purity660, Batterbind S.C., Penbind 100, MiraQuick MGL, Novation 3300, andGel-n-Melt. A suitable commercially-available native (unmodified) starchis Hylon V.

Mira-Cleer 516, from A. E. Staley Company, is a dent corn starch that iscross-linked and substituted with hydroxypropyl groups. Thecross-linking increases its gelatinization temperature and acidtolerance. The hydroxypropyl substitution increases its water bindingcapability, viscosity and freeze-thaw stability. MiraQuick MGL, alsofrom A. E. Staley Company, is an acid-thinned potato starch. The acidthinning breaks amylopectin branches in the starch, creating a firmergel. Batterbind S.C., from National Starch, is a cross-linked andoxidized dent corn starch. Purity 660, also from National Starch, is across-linked and hydroxypropyl substituted dent corn starch. Hylon V,also from National Starch, is an unmodified, high amylose corn starch.Pencling 200, from Penwest Foods, is an oxidized potato starch. Theoxidation increases its capacity to bind water and protein. Penbind 100,also from Penwest Foods, is a cross-linked potato starch.

Emulsifiers, Gelling Agents, Stabilizers and Thickeners. Gums,celluloses, and alginates are some examples of emulsifiers, gellingagents, stabilizers and thickeners. Many of the considerations thatapply to starches also apply to gums and celluloses. Certain gums andcelluloses, for example, should be hydrated and/or heated to realizetheir full functional characteristics. Heating and hydration alsoenables increased levels of the gums, celluloses, or alginates to beincluded in the final product. Some of the soft and firm/semi-hardcheeses that are provided herein contain at least about 0.01, 0.1, 0.5or 3.0 wt. % gum, cellulose, or alginate. The products thus generallyhave a gum, cellulose, or alginate concentration of about 0.01-3.0 wt.%.

Different types of celluloses can also be incorporated into the cheese.The cellulose can be either natural or modified. One cellulose orcombinations of different celluloses can be utilized. Types ofcelluloses that can be utilized include, but are not limited to,microcrystalline cellulose, powdered cellulose, methyl cellulose,propylene glycol alginate, and sodium alginate. One specific example ofa commercially available modified cellulose is METHOCEL A-15™ that isavailable from Dow Chemical Company (Midland, Mich.).

Examples of suitable gums that can be incorporated include, but are notlimited to, xanthan gum, guar gum, konjac flour and locust bean gum.Examples of suitable stabilizers include chondrus extract (carrageenan),pectin, gelatin, and agar.

The total amount of gums and stabilizers included in the final cheeseproduct is typically up to about 0.01, about 0.50, or about 3.0% byweight. More specifically, the amount of gums and/or stabilizers canrange from about 0.01 to 3.0%, from about 0.25 to 2.5%, or from about0.5 to 2.0% by weight of the final cheese product.

Acidity Regulators, Anticaking Agents, and Firming Agents. Acidityregulators, anticaking agents, and firming agents of various types canbe included in the cheese. Typically, these agents are inorganic salts,but other types of acidity regulators, anticaking agents, and firmingagents can also be used. Examples of acidity regulators, anticakingagents, and firming agents may include calcium chloride, tricalciumphosphate, calcium hydroxide, powdered cellulose, disodium phosphate,and potassium hydroxide. These agents are typically added as part of asolution, (but could be used as a powder).

The total amount of acidity regulators, anticaking agents, and firmingagents incorporated into a slurry is sufficient so the concentration ofthe acidity regulators, anticaking agents, and firming agents in thefinal cheese product is generally up to about 0.05, 1.2, or 3.0% byweight. More specifically, the amount of acidity regulators, anticakingagents, and firming agents can range from about 0.05 to 3.0%, from about0.1 to 2.5%, or from about 0.5 to 2.0% by weight.

Sequestrants. A number of different sequestrants can be incorporatedinto the final cheese product. Sequestrants that can be utilizedinclude, but are not limited to, various phosphate salts (e.g., sodiumhexametaphosphate, monosodium phosphate, sodium tripolyphosphate,disodium phosphate, trisodium citrate and potassium phosphate), calciumcitrate, calcium gluconate, oxystearin and sorbitol.

The total amount of sequestrant is usually up to about 0.1, 1, or 4% byweight of the final cheese product. So, for example, the amount ofsequestrant in the final cheese product can range from about 0.1 to 4%,from about 0.25 to 3.0%, or from about 0.4 to 2.5% by weight.

Acids. An acid can be incorporated to adjust the pH of the finishedcheese to a desired level. Various acids can be employed; examples ofsuitable acids include, but are not limited to, adipic acid, lacticacid, glucono-delta-lactone, phosphoric acid, lactobionic acid,hydrochloric acid, acetic acid, or Genlac C, the latter being a blend ofwater, citric acid, lactic acid, acetic acid and artificial flavors.Acid is typically added to adjust the pH of the finished cheese to a pHfrom about 5-6, and more typically from pH 5.10-5.70. An acid is addedto the slurry as a processing aid to cause a reduction in slurryviscosity before cooking, making the slurry easier to pump through thecooker and other system equipment.

Cheese powders. Cheese powders can also be mixed into the cheese toimpart a different cheese flavor to the finished product. Such powdersare typically added to the heated cheese mass formed during the pastafilata process as a powder rather than as part of the slurry.

Examples of suitable cheese powders include, but are not limited to,Parmesan, cheddar, Monterey Jack, Romano, muenster, Swiss, and provolonepowders. The amount of cheese powder in the finished cheese is generallyabout 0.25 to 10%, and in some instances about 1.05 to 5% by weight.Cheese powders are available from a variety of commercial suppliers,including, for example, Armour Foods of Springfield, Ky.

Colorants. A colorant can be incorporated into the cheese to adjust itsnatural color. This can be useful, for example, if consumers have apreference for a color other than the naturally-occurring color.Examples of suitable colorants include annatto, tumeric, titaniumdioxide, and beta-carotene. Colorants may be of both the natural orartificial color. If one wished to color the cheese a red an artificialcolor such as FD&C red # 40 can be used. Annatto is useful to givemozzarella cheese the appearance of cheddar. This allows one to producea cheese for pizza baking that has the desired melt characteristics ofmozzarella, but with a different appearance than that of traditionalwhite mozzarella. Annatto-colored mozzarella can be used as areplacement for cheddar cheese in many food products (e.g.,Mexican-style prepared foods). Tumeric imparts a yellowish color tomozzarella, which naturally is white. The yellowish color often ispreferred by consumers who perceive it to indicate a “richer” productupon cooking on a pizza. Colorants such as annatto and tumeric can beobtained, for example, from Chris Hansens Labs of Milwaukee, Wis.

Colorants can be incorporated into the final cheese product by inclusionin the slurry. If added apart from the slurry, the colorant is generallysprayed onto the heated cheese mass as an unheated solution ordispersion in water. The amount of colorant added is typically in therange of about 0.01 to 2%, based on the weight of the finished cheese.Tumeric, if used, is generally added in an amount of about 0.05 to 0.2%.If annatto is added, it normally is added to about 0.1 to 0.3% byweight.

Flavoring Agents. Various flavoring agents can also be incorporated intothe cheese to tailor the flavor profile of the cheese to meet consumerpreferences. Suitable flavors for mixing into the heated cheese include,for example, cheddar cheese flavor and parmesan cheese flavor. Flavoringagents are typically added in an amount such that the concentration inthe final cheese product is within the range of about 0.01 to 5 wt. %.

Non-dairy protein isolate. A non-dairy protein isolate can also beincorporated into the cheese. It is to alter the texture of the cheeseand/or to change the size, color, or integrity of the blisters that areformed when the cheese is baked on a pizza, as well as other cookcharacteristics. Examples of suitable non-dairy protein isolatesinclude, but are not limited to, soy protein (sometimes called “soypowder”), gelatin, wheat germ, corn germ, gluten, and egg solids.

The protein isolate is added such that the concentration of the proteinisolate in the final cheese product is up to about 1, 15 or 30 wt. %.

Oils. Various oils can also be incorporated into the cheese. They aregenerally added to alter the fatty acid profile and/or cost of thecheese and/or to change the size, color, or integrity of the blistersthat are formed when the cheese is baked, as well as other cookcharacteristics. Examples of suitable oils include, but are not limitedto, vegetable oil, soy bean oil, corn oil, flax seed oil, walnut oil,palm oil, linoleic acid, fish oil, omega 3 fatty acids, and medium chaintriglycerides, among others. Any of the oils may be partially orcompletely hydrogenated. If blended into the initial slurry, the oil isadded in a concentration such that the concentration of the oil in thefinal cheese product is up to about 1.0, 20 or 35 wt. %.

Salt. Salts of various types, but typically sodium chloride, can beadded to tailor the flavor of the final cheese. The salt can beincorporated into the final cheese product by including it in the heatedslurry or by adding it in granular form or as an unheated solution apartfrom the slurry. Regardless of how introduced, the salt concentration inthe final cheese product is usually added at a level of about 0.1-5 wt.%. When added as an ingredient of the slurry, this means that the saltconcentration in the slurry is generally about 0.1 to 2.0 wt. %.

Antifoaming Agents. Various antifoaming agents can be incorporated tofacilitate processing. Examples include, but are not limited to,microcrystalline wax, oxystearin and polydimethylsiloxane.

Carbohydrates. A variety of simple sugars (e.g., mono- anddisaccharides), as well as more complex carbohydrates can be included inthe cheese. Examples include, but are not limited to, glucose, sucrose,and fructose.

Enzymes. Enzymes may be used to create flavors, texture, melt, and/orother functional characteristics in the final cheese product, and/or inthe slurry that can then be transferred to the final cheese product oncethe slurry and cheese have been mixed together. Examples of suchenzymes, and this is not an all inclusive list, would be lipases,proteases, oxidoreductases, and transglutaminase.

Neutraceuticals. Neutraceuticals may be included to deliver nutrientsnot normally present in cheese. Examples of neutraceuticals include, butare not limited to lycopene, antioxidants, probiotics, prebiotics,phosphatidylserine, vegetable sterols, immunoglobulins. These productsin particular may be added as part of the slurry or to the mixer (mixer190, FIG. 4).

IV. Slurries

Compositions in the form of slurries that contain one or more of theingredients listed in the preceding section are also provided. Theslurries primarily are comprised of molten cheese curd and optionallywater. But the slurries can also include one or more of the ingredientslisted in the preceding section in the concentration ranges listed. Curdmakes up about 25-100 wt. % of the slurry, and water about 0-10 wt. % insome slurries.

V. Systems for Preparing Soft or Firm/Semi-Hard Cheese

One general system for preparing a soft or firm/semi-hard cheese isshown in FIG. 5. This particular system 201 includes a cooker 207 thatcan cook cheese curd without exogenous water. This cooker 207 isconnected to a final processing system 300 via transfer tube 299. Thecooker 207 may also be connected to another transfer tube (not shown)that delivers the curd, and optional ingredients, to the cooker 207.Systems such as this are useful for performing methods such as depictedin FIG. 1A, for example.

FIG. 6 depicts another example of a generalized system that can be usedto carry out the foregoing methods to prepare soft and firm/semi-hardcheeses such as are described herein. As this figure illustrates, onesystem design 200 involves the following basic subsystems: (1) a slurrypreparation system 205, (2) a mixer 290, (3) additive dispenser 286, and(4) a final processing system 300.

In exemplary system 200, slurry preparation system 205 is used to blendtogether the cheese curd, and optionally a liquid (e.g., water) andingredient(s), to prepare the initial slurry. This preparation system205 is in communication with mixer 290 via transfer tubes 255. Additivedispenser 286 is connected with mixer 290 via transfer tube 287. Mixer290 is also in communication with final processing system 300. Thus, theadmixture formed by the mixing of the slurry and ingredients introducedby the additive dispenser in mixer 290 can be transported to finalprocessing system 300 via transfer tube 295. In the final processingsystem 300, the admixture is shaped and cooled to form the final soft orfirm/semi-hard cheese product.

A wide variety of different systems that are provided herein have thisgeneral design. Although specific examples of such systems are describedbelow, it should be understood that these systems are only examples andnot intended to be exhaustive of the types of systems that can be usedto carry out the cheese processing methods that are described herein orof the type of systems that can be used to prepare the type of cheesesthat are disclosed herein.

One exemplary system 202 is shown in FIG. 7. The slurry preparationsystem 205 in this particular system includes several components tocook, shear, homogenize and/or adjust the water content of the slurrythat is prepared. More specifically, slurry preparation system 205 inthis system includes slurry mixing and moisture control subsystem 208.The particular subsystem 208 shown in FIG. 7 includes shear pump 230,homogenizer 240 and evaporator 250. Subsystem 208 is in communicationwith cooker 220 and mixer 290.

In the particular subsystem shown in FIG. 7, shear pump 230 of subsystem208 is connected to cooker 220 via transfer tube 225 to establish a linkbetween the cooker and the subsystem. Shear pump 230 is also connectedto homogenizer 240 by transfer tube 235, with homogenizer 240 in turnconnected to evaporator 250 by transfer tube 245. Evaporator 250 isconnected to mixer 290 by transfer tube 255, thus establishing theconnection between subsystem 208 and mixer 290. Slurry preparationsystem 205 also includes ingredient dispenser 207 that is connected toblender 210 via tube 209.

Thus, in the arrangement shown in FIG. 7, the initial slurry formed inblender 210 can flow to cooker 220 via transfer tube 215. The heatedslurry from cooker 220 can subsequently flow into shear pump 230 viatransfer tube 225, where the slurry is subjected to the shear conditionsdescribed above. The sheared slurry can subsequently be transferred tohomogenizer 240 through transfer tube 235, where the slurry and theingredient(s) it contains are homogenized. The resulting homogenizedslurry is then transported through transfer tube 245 into evaporator250. Evaporator 250 adjusts the moisture content within the rangeslisted above. The final slurry then passes from evaporator 250 intomixer 290 via transfer tube 255.

Additional ingredients can be added from additive dispenser 286 to mixer290 by transfer tube 287. The slurry and ingredients are mixed in mixer290 to form the admixture. The admixture formed in mixer 290 can then beprocessed (e.g., extruded and cooled) in final processing system 300.Alternatively, the transfer tube 291 may divert the flow of theadmixture between coloring units 293 and 294. Coloring unit 293 may addcoloring (e.g., orange) to the admixture to give it the appearance of,for example, cheddar cheese, while coloring unit 294 may add no colorand leave the cheese substantially white in color. The entire admixturemay be diverted through one or the other coloring units 293 and 294, aswell as being adjustable to split the admixture between the coloringunits to create, for example, a cheese combination from the admixture.The admixture may then go to the final processing system 300.

It will be appreciated by those of ordinary skill in the art thatcertain units within slurry preparation system 205 (e.g., cooker 220,shear pump 230, homogenizer 240 and evaporator 250) can be arranged in avariety of other configurations. For instance, although shown asseparate units in FIG. 7, shear pump 230 and homogenizer 240 can be partof a single unit in other systems. Other exemplary combinations that canoptionally be utilized in still other systems are those in which cooker220 and shear pump 230 are part of the same unit, and systems in whichcooker 220, shear pump 230 and homogenizer 240 are all part of the sameintegrated unit.

The order in which cooker 220, shear pump 230 and homogenizer 240 appearin FIG. 7 can also be altered in other systems such that all the variouspermutations are possible. Examples of optional arrangements that can beutilized in other systems include: 1) cooker-homogenizer-shear pump, 2)shear pump-homogenizer-cooker, 3) shear pump-cooker-homogenizer, 4)homogenizer-shear pump-cooker, 5) homogenizer-cooker-shear pump, and theother various permutations.

Some systems do not include shear pump 230, homogenizer 240 andevaporator 250, but instead simply include blender 210 and cooker 220.Other systems include just blender 210.

Different types of blenders can be used to mix the ingredients togetherto form the initial slurry. In general, the blender simply needs to becapable of mixing relatively viscous materials. Some blenders arehorizontal twin screw (auger) types. Ribbon blenders or pipelines thatinclude a series of pumps and static mixers can also be utilized.

The cooker used in these systems can be of various types, includinglay-down cooker, swept surface heat exchanger, agitated direct heatingpipeline cooker. The cookers are capable of heating a slurry of thecompositions defined herein to temperatures ranging from about 90-293°F. (32-145° C.). Specific examples of suitable cookers include theRotaTherm™ cooker available from Gold Peg International Pty. Ltd.(Moorabbin, Vic, Australia), the FusionCooker™, available from BlentechCorporation, (Rohnert Part, Calif.), or a continuous mixer from READCOManufacturing (York, Pa.), or Exact Mixing Systems (Memphis, Tenn.), ora single or twin screw extruder from Clextral Inc., (Tampa, Fla.). Thecookers can heat the slurry by convection (e.g., a heated blanketsurrounds the cooker) or by directly injecting steam into the cooker,radiation (e.g., microwave), or combinations of direct/indirect,radiation, and mechanical heating.

Various types of shear pumps can be utilized. Suitable types of shearpumps include in-line mixers, colloid mills, etc. Examples of pumps thatcan be used include a high shear in-line mixer available from Silverson(East Longmeadow, Mass.) and an in-line mixer from Scott Turbon(Adelanto, Calif.). The shear pump should be capable of generating shearforces of at least 5,000 to greater than 1,000,000 s⁻¹.

A number of homogenizers are also suitable for use in the systems thatare provided. Examples of homogenizers that can be used include a Gaulinhomogenizer available from Gaulin (Kansas City, Mo.) and homogenizerfrom Waukesha Cherry Burrell (Charlotte, N.C.).

Evaporators of different types can also be utilized. In general, theevaporator should be able to handle relatively viscous solution. Flashvacuum vessels are one example of a suitable evaporator. Evaporators ofthis type are available from De Dietrich Process Systems (Bridgeton,Mo.). Some systems include a feedback system that is connected to theevaporator (e.g., a near infrared monitor). This system may include asensor that can monitor the moisture level in the slurry coming from theevaporator and send a signal to the evaporator signaling the evaporatorto increase, decrease or maintain the level at which water is removedfrom the slurry so the desired moisture content in the slurry isachieved.

The specific design of the final processing system can vary, but caninclude a pre-brine tank that includes super cold sodium chloride brineinto which molten cheese or cheese ribbons can flow. A cutter can cutthe cheese into loaves as the cheese ribbon exits the pre-brine tank.The cooled and salted loaves are then transferred to a main brine tankwhere they stay until removed by a conveyor. An exemplary system of thisgeneral design is described in U.S. Pat. No. 5, 902,625, which isincorporated herein by reference in its entirety for all purposes.

VI. Soft or Firm/Semi-hard Ripened or Unripened Cheese

The methods that are described herein can be utilized to prepare cheesesthat contain one or more of the ingredients at the concentration rangesdescribed herein. As indicated above, some of the methods that aredisclosed herein can be utilized to manufacture cheeses that containingredients that become functionalize when included in a slurry and aresubject to heating and/or hydration. Some of the cheeses can alsoinclude relatively high concentrations of certain ingredients.

The soft or firm/semi-hard cheeses that are provided typically have aprotein content of about 10-40 wt. %, a moisture content of about35-65%, and a fat content of about 0-60% on a dry basis (FDB). Theactual composition varies somewhat depending upon the particular type ofsoft or firm/semi-hard cheese that is to be produced. For certain softor firm/semi-hard cheeses that are provided, the milk fat content is atleast 45% by weight of solids and the moisture content is about 52-60wt. %. The low-moisture soft or firm/semi-hard cheeses (also sometimesreferred to as low-moisture mozzarella cheeses) that are providedgenerally have a minimum milk fat content of 45% by weight of solids anda moisture content that is about 45-52 wt. %. Part skim-milk soft orfirm/semi-hard ripened and unripened cheeses (also called part skimmozzarella cheeses) that are provided, in contrast, have a milk fatcontent that ranges from about 30-45% by weight of solids and a moisturecontent that is about 52-60 wt %. The low-moisture, part-skim soft orfirm/semi-hard ripened and unripened cheeses (also referred to aslow-moisture, part skim mozzarella cheeses) that are provided usuallyhave a milk fat content of about 30-45% by weight of the solids and amoisture content of about 45-52 wt %. The foregoing moisture percentagesare for bound plus free water, i.e., the percent of weight lost when thecheese is dried for 17 hrs±1 hr in a 100° C. oven.

The cheeses that are provided can be in a variety of different formsincluding loaves, Ribbons™, comminuted forms (e.g., diced, sliced, orshredded forms) and other forms known in the art. The pH of the cheesegenerally ranges from about 5.00 to about 6.00, such as about 5.10 toabout 5.90.

VII. Food Products and Methods of Manufacturing Such Food Stuffs

The soft or firm/semi-hard cheeses that are provided can be utilized inessentially baking application that involves the use of cheese and canbe incorporated into a wide variety of food products. The cheeses, forinstance, can be included as an ingredient in a variety of conveniencefoods, including entrees, snack foods and appetizers.

The term “food product” is intended to broadly encompass any type offood to which one can add cheese. Examples of suitable types of foodsinto which the provided cheeses can be added, include, but are notlimited to: cereal-based products; poultry, beef, pork or seafood-basedentrees; potatoes; vegetables; fruit; candy; and nuts. The cereal-basedproducts can be of diverse types including, for instance, pizzas,burritos, dough-enrobed sandwiches, hand-held foods, breads, bagels,pastries, and grain-based snack foods (e.g., crackers and pretzels). Thecheese can be included with a variety of different forms of potatoes,including, chips, French fries, hash browns, and strings. Likewise,vegetables of various types can be combined with the cheeses that areprovided. Exemplary vegetables include, mushrooms, zucchini, peppers(e.g., jalapenos) and cauliflower.

The cheeses can be incorporated into the food product, layered onto orin the foodstuff or used as a coating. One common use, for example, isas an exposed cheese on a pizza or as the string cheese rolled in theouter lip of a pizza crust (a so-called “stuffed crust pizza”).

As those skilled in the art will recognize, the foregoing list is simplyillustrative and is not intended to be an exhaustive list of the typesof foods that can be combined with the soft or firm/semi-hard cheesesthat are provided herein.

The cheeses that are provided are suitable for use in essentially anytype of cooking including convection heating, steam injection heatingand microwave heating, for example. In some microwave heatingapplications, for example, the food product is exposed to microwaveenergy in an amount and for a duration sufficient to heat and melt thecheese, whereby the cheese melts to form a uniform mass of cheese. Thecheeses can generally be heated in a variety of microwaves, such asmicrowaves having wattages of 400-1000 watts, or full power microwaveovens of 650-850 watts that are common home microwave ovens. The cheesescan be cooked over a range of cooking times such as from 0.5 to 20minutes, or 0.5-10 minutes, or 2-5 minutes, which are the typicalmicrowave cook times used to prepare frozen or refrigerated entrees andappetizers.

The soft or firm/semi-hard cheeses that are disclosed herein can becombined with food products such as those just listed using any of avariety of methods. For example, the food product can be dipped inmelted cheese. Alternatively, the cheese can be sprinkled or layeredonto the food product using conventional food processing equipment. Insuch processes, the cheese is typically first comminuted to formrelatively small pieces of cheese or shredded cheese. Once the cheesehas been combined with the food product, the resulting food product canoptionally be refrigerated or frozen for future sale or use.

EXAMPLES

Shred qualities and melt grades for four different production runs ofMozzarella cheeses were measured and compared. In all four examples,non-fat dry milk (NDM) was incorporated into the Mozzarella cheese. Intwo of the examples (Examples A and B), 6.0%, by weight, of NDM wasadded to the cheese, while for the other two examples (Examples C andD), 12.0%, by wt., NDM was added. In two of the examples (Examples A andC), the NDM was added to the Mozzarella cheese directly as a dry powder,while in the other two examples (Examples B and D) the NDM was mixedinto the Mozzarella curd and heated to less than 150° F. (65.6° C.) inthe absence of exogenous water to form the final Mozzarella product.Table 1 lists the conditions for each of the four Examples A-D:

TABLE 1 Processing Parameters for Runs A-D Run No. Wt. % NDM Added NDMAddition Method A 6.0% NDM Powder Added to Mozzarella Cheese B 6.0% NDMAdded to Mozzarella Curd & Heated In Absence of Exogenous Water C 12.0%NDM Powder Added to Mozzarella Cheese D 12.0% NDM Added to MozzarellaCurd & Heated In Absence of Exogenous Water

For all the runs, the Mozzarella cheeses used conventional startercultures to produce cheeses with target compositions of 49.0% moisture,40.0 FDB, 5.35 pH, and 1.80% salt. Ribbon™ cheese (7×9×2-inches) wasextruded, and the packaged cheese samples were stored at 35° F. (1.7°C.) for 14 days. The cheese samples were shredded into cuts (1.25-3inches×0.20 inches×0.095 inches) on an Urchell CC shredder (UrchellLaboratories, Inc. Indiana, USA). The shredded cheese cuts were frozenindividually and stored at −20° F.

Two-pound samples of cheese were removed, thawed at 35° F. (1.7° C.),and melted on both frozen pizzas and food service pizzas. The cheesesmelted on a frozen pizza had 5.6 ounces of frozen cheese placed on aready-made crust and 3 ounces of sauce and frozen for 24 hours prior tomelting in a home oven at 425° C. for 19 minutes. The cheeses melted onfood service pizzas had 7 ounces of cheese on a regular pizza crust,together with 4 ounces of pizza sauce. The pizzas were cooked on aconveyor-bake pizza (Middleby Marshall oven at 420° F. (215.6° C.) for 6minutes 30 seconds).

The shred cut qualities and melt grades of the cheeses produced inExamples a-d were then measured. The melt grade measurements of thecheeses on the service oven pizzas and cooked frozen pizzas includedcomparisons of the blister color, blister %, blister size, melt,stretch, and oiling-off. The melt grade measurements were made with a20-point scale, with 10 being the best grade, while 1 is too little, and20 is too much. Table 2 summarizes the melt grade grading system:

TABLE 2 Melt Grade Grading System NONE SLIGHT MODERATE DEFINITEPRONOUNCED Score 1 to 4 5 to 8 8 to 12 12 to 16 16 to 20 Blister % 0-10%10-25% 25-50% 50-75% >75% Blister Size ⅛ to ¼′ ⅜ to ½′ ⅝ to ¾′ ⅞ to1′ >1′ Blister Color Light Golden Golden to Light Golden Brown DarkBrown Black Oiling Off None Even sheen over cheese Some minor areasNoticeable collection areas Entire surface heavily surface with slightpooling coated with oil Meltdown Cheese does not fuse Appeals fusedtogether Cheese completely Cheese is slightly soupy Cheese is veryrunny, together after cooking but shows minor jigsaw fused together andsauce appears to bleed soupy and appears weak appearance through in bodyStretch 0 to 1′ 1½ to 3′ 3 to 5′ 5 to 7′ >7′

The shred quality measurements of the cheeses included comparisons ofshred quality and shred compaction. These measurements were made on a4-point scale with 1 being the best, and 4 being the least acceptable.Table 3 summarizes the results of the melt grade and shred qualitymeasurements for Examples A-D.

TABLE 3 Shred Quality and Melt Grades Food Service Pizza Cut QualityBlister Blister Blister Oiling Frozen Pizza Shred % Size Color Off MeltStretch Blistering Melt Stretch Compaction Quality Example a. 6.0% NDM 31 14 4 10 12 1 7 8 1.5 2.0 added as powder Example b. 6.0% NDM 7 3 16 29 8 1 9 6 2.0 2.0 added to curd and heated Example c. 12.0% NDM 4 2 15 312 8 3 12 6 2.0 2.5 added as powder Example d. 12.0% NDM 10 4 18 1 6 4 14 2 2.5 3.0 added to curd and heated

The cheeses prepared by mixing and heating NDM and Mozzarella cheesecurd in the absence of exogenous water, can also increase the yield ofthe finished cheese. When the Mozzarella curd is placed in a wet mixerfor kneading and plasticizing, the hot (e.g., 152° F. to 160° F.)exogenous water contacting the curd can absorb some curd materials, suchas butterfat, protein, total solids, etc. Post wet mixing analysis ofthe exogenous water shows the water contained an average of 1.09% fat,0.33% protein, and 4.41% total solids from the Mozzarella cheese curd.This represents about 17.6 lbs of lost curd materials for an averageamount of exogenous overflow liquid collected. If these materialsremained in the curd, the yield of the finished cheese increases 1.2%,by weight. This is the increased yield of finished cheese realized byheating and mixing the NDM and cheese curd in the absence of exogenouswater.

The pictures of the sample cheeses shown in FIGS. 8A-B illustratequality differences between cheese prepared by adding NDM as a drypowder directly to Mozzarella, and those prepared by adding the NDM tocheese curd that is then heated in the absence of exogenous water. Thedirect addition of dry powder NDM resulted in powdered lumps forming inthe finished cheese as shown in FIG. 8A. These lumps can break dicerblades during the shredding process and diminish product quality fromthe customer prospective. In contrast, the same levels of NDM added toMozzarella cheese curd, which was then heated to less than 150° F.,resulted in a smooth, homogenous finished cheese without powdered lumps,as shown in FIG. 8B.

It is understood that the examples and embodiments described herein arefor illustrative purposes only and that various modifications or changesin light thereof will be suggested to persons skilled in the art and areto be included within the spirit and purview of this application andscope of the appended claims. The cheeses of the present invention maybe made by the methods described herein, or by any other method thatproduces a finished cheese product having the same physical or chemicalproperties as the present cheeses. All publications, patents and patentapplications cited herein are hereby incorporated by reference in theirentirety for all purposes to the same extent as if each individualpublication, patent or patent application were specifically andindividually indicated to be so incorporated by reference.

1. A cheese manufacturing system, comprising: (a) a slurry preparationsystem to prepare a slurry in the absence of a cheese mass comprising(i) a blender adapted to blend a cheese curd and one or more ingredientstogether to form a slurry, wherein the blender does not substantiallyalter the size of the ingredients which are solid, (ii) a firstdispenser operatively disposed to introduce the one or more ingredientsinto the slurry, and (iii) a subsystem comprising at least one of thefollowing units a cooker adapted to heat the slurry to a temperature ofabout 90° F. to about 293° F.; a shear pump adapted to subject theslurry to high shear conditions; a homogenizer adapted to homogenize theone or more ingredients in the slurry; and an evaporator adapted toadjust the water content of the slurry to about 35-65% by weight,wherein the at least one unit is in communication with the blender andthe units within the subsystem are in fluid communication; (b) a seconddispenser; (c) a mixer operatively disposed to receive the slurry fromthe slurry preparation system and to receive one or more ingredientsfrom the second dispenser, and adapted to mix the slurry with the one ormore ingredients to form an admixture; and (d) a final processing systemoperatively disposed to receive the admixture and adapted to form afinal cheese product.
 2. The system of claim 1, wherein the subsystemincludes the cooker, the shear pump, the homogenizer and the evaporator.3. The system of claim 1, wherein the heater is operatively disposed toreceive the slurry from the blender; the shear pump is operativelydisposed to receive the slurry from the heater; the homogenizer isoperatively disposed to receive the slurry from the shear pump; and theevaporator is operatively disposed to receive the slurry from thehomogenizer and is in communication with the mixer.
 4. The system ofclaim 1, wherein the evaporator is a flash vacuum vessel.
 5. A cheesemanufacturing system, comprising: (a) a slurry preparation system toprepare a slurry in the absence of a cheese mass comprising (i) ablender adapted to blend a cheese curd, and optionally one or moreingredients together to form a slurry, wherein the blender does notsubstantially alter the size of the ingredients which are solid, (ii) acooker that is operatively disposed to receive the slurry from theblender and adapted to heat the slurry to a temperature of about 90° F.to about 293° F., and (iii) a slurry mixing and moisture controlsubsystem, which comprises one or more of the following units (i) ashear pump adapted to subject the slurry to high shear conditions; (ii)a homogenizer adapted to homogenize the slurry; and (iii) an evaporatoradapted to adjust the water content of the slurry to about 35-65% byweight, wherein the subsystem is in communication with the cooker andthe units within the subsystem are in fluid communication; and (b) afinal processing system operatively disposed to receive the slurry fromthe slurry preparation system and adapted to form a final cheeseproduct.